Method for manufacturing of display device

ABSTRACT

A method for manufacturing a display device is provided. A process of forming an inspection pattern, in which a protective film unit is partially removed in a thickness direction, in a pad area portion of the protective film unit, which corresponds to a pad area of a display unit, may be performed, and then, a process of delaminating the pad area portion of the protective film unit may be performed. A process of checking whether the inspection pattern exists may be performed to check whether the delamination has succeeded, and, at the same time, a process of measuring distances from an alignment mark to each of a long side and a short side of the display unit may be performed.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/973,302, filed on May 7, 2018, which claims priority to and thebenefit of Korean Patent Application No. 10-2017-0118868, filed on Sep.15, 2017 in the Korean Intellectual Property Office, the entire contentof each of which is hereby incorporated by reference.

BACKGROUND 1. Field

Aspects of embodiments of the present disclosure relate to a method formanufacturing a display device.

2. Description of the Related Art

In recent years, various kinds of panels are being used in a field ofmanufacturing a display device, such as a liquid crystal display (LCD),an organic light emitting diode (OLED), and a touch screen panel (TSP).

During such a manufacturing process, the process is performed whilemoving to various spaces. A protective film is attached onto a surfaceof a display device to prevent the surface of the display device frombeing polluted or damaged while moving the display device to anotherspace, and such a protective film is necessarily removed in a process ofconnecting inner wires or pads. Accordingly, a device for delaminatingthe protective film attached to a surface of a panel is being suggested.

A contact-type inspection using a method of applying a pressure on a padpart is performed to inspect whether delamination has occurred after theprocess of delaminating the protective film attached to the pad partarea of the display device, and, during this process, a crack may begenerated in the pad part due to an error of a pressure sensor.

SUMMARY

According to an aspect of embodiments of the present disclosure, amethod for manufacturing a display device is provided, by which aninspection of whether a pad part of a display substrate is delaminatedis easily performed.

According to another aspect of embodiments of the present disclosure, amethod for manufacturing a display panel is provided, by which a failureof the display panel may be prevented during a manufacturing process.

According to one or more embodiments of the inventive concept, a methodfor manufacturing a display device includes: providing a work panelincluding a work substrate including a plurality of display units eachincluding a display area and a pad area, and a work protective filmattached onto the work substrate; separating a plurality of displaypanels from the work panel, each including a display unit of theplurality of display units and a protective film unit of the workprotective film overlapping on the display unit on a plane; forming acutting line in the protective film unit so as to correspond to aboundary between the display area and the pad area; forming aninspection pattern, in which the protective film unit is partiallyremoved in a thickness direction, in a pad film area portion of theprotective film unit, which corresponds to the pad area of the displayunit; delaminating the pad area portion of the protective film unitalong the cutting line; and checking whether the inspection patternexists in the pad film area of the display unit.

In an embodiment, the pad area may include a plurality of wires and aplurality of alignment marks, and the inspection pattern may overlap atleast one of the plurality of alignment marks.

In an embodiment, the inspection pattern may overlap at least one of theplurality of wires.

In an embodiment, the plurality of alignment marks may be formed on asame layer as that of a wire of the plurality of wires.

In an embodiment, the method may further include measuring distancesfrom an alignment mark of the plurality of alignment marks to each of along side and a short side of the display unit.

In an embodiment, measuring distances from the alignment mark to each ofthe long side and the short side of the display unit and checkingwhether the inspection pattern exists may be performed at the same time.

In an embodiment, an adhesive layer may be between the protective filmunit and the display unit, and wherein the cutting line is formed bycompletely removing the protective film unit in a thickness direction ofthe display panel to expose the adhesive layer to the outside.

In an embodiment, the adhesive layer exposed to the outside by thecutting line may have a thickness of 25 μm to about 40 μm.

In an embodiment, the display unit may include a base substrate, acircuit element layer, a display element layer, and a thin-filmencapsulation layer, which are sequentially laminated.

In an embodiment, the method may further include a work protective filmattached to a bottom surface of the work panel.

According to one or more embodiments of the inventive concept, a methodfor manufacturing a display device includes: providing a display unitincluding a display area and a pad area; attaching a protective filmunit including a first area and a second area respectively correspondingto the display area and the pad area onto the display unit; forming acutting line so as to correspond to a boundary between the first areaand the second area; forming an inspection pattern, in which theprotective film unit is partially removed in a thickness direction, onthe second area of the protective film; delaminating the protective filmunit corresponding to the second area along the cutting line; andchecking whether the inspection pattern exists on the pad area.

In an embodiment, the pad area may include a plurality of alignmentmarks, and the inspection pattern may overlap at least one of theplurality of alignment marks.

In an embodiment, the method may further include measuring distancesfrom the at least one alignment mark to each of a long side and a shortside of the display unit.

In an embodiment, measuring distances from the at least one alignmentmark to each of the long side and the short side of the display unit andchecking whether the inspection pattern exists may be performed at thesame time.

In an embodiment, the pad area may include a plurality of wires, and theinspection pattern may overlap at least one of the plurality of wires.

In an embodiment, an adhesive layer may be between the protective filmunit and the display unit, and wherein the cutting line is formed bycompletely removing the protective film unit in a thickness direction ofthe display panel to expose the adhesive layer to the outside.

In an embodiment, the display unit may include a base substrate, acircuit element layer, a display element layer, and a thin-filmencapsulation layer, which are sequentially laminated.

According to one or more embodiments of the inventive concept, anequipment for manufacturing a display device includes: a laser deviceconfigured to form an inspection pattern by cutting a work substrate anda work protective film attached onto the work substrate and separatingthe same into a plurality of display units each including a display areaand a pad area and protective film units respectively attached to theplurality of display units and comprising a first area and a secondarea, each of which overlaps the display area and the pad area on aplane, completely removing the protective film unit in a thicknessdirection in an area corresponding to a boundary between the first areaand the second area to form a cutting line, and partially removing theprotective film unit in a thickness direction in an area correspondingto the second area; a delamination device configured to remove theprotective film unit corresponding to the second area along the cuttingline, wherein the pad area includes a plurality of alignment marks; aninspection device configured to recognize the alignment marks anddetermine whether the inspection pattern exists; and a control deviceelectrically connected to the laser device, the delamination device, andthe inspection device to control the laser device, the delaminationdevice, and the inspection device.

In an embodiment, the laser device may irradiate lasers havingintensities different from each other to at least one of separate theprotective film unit, form the cutting line, or form the inspectionpattern.

In an embodiment, the inspection device may include a camera module andconcurrently recognize the alignment marks and whether the inspectionpattern exists through the camera module.

BRIEF DESCRIPTION OF THE FIGURES

The accompanying drawings are included to provide a furtherunderstanding of the inventive concept, and are incorporated in andconstitute a part of this specification. The drawings illustrate someexemplary embodiments of the inventive concept and, together with thedescription, serve to explain principles of the inventive concept. Inthe drawings:

FIG. 1 is a plan view illustrating a process of providing a worksubstrate according to an embodiment of the inventive concept;

FIG. 2 is a plan view of a display unit according to an embodiment ofthe inventive concept;

FIG. 3 is an equivalent circuit diagram of a pixel according to anembodiment of the inventive concept;

FIG. 4 is a plan view illustrating a process of attaching a workprotective film according to an embodiment of the inventive concept;

FIG. 5 is a cross-sectional view of a display unit, taken along the lineI-I′ of FIG. 4, according to an embodiment of the inventive concept;

FIG. 6 is a plan view illustrating a process of separating a pluralityof display panels from the work panel according to an embodiment of theinventive concept;

FIG. 7 is a plan view of a display panel on which a cutting line isformed according to an embodiment of the inventive concept;

FIG. 8 is a plan view of a display panel on which an inspection patternis formed according to an embodiment of the inventive concept;

FIG. 9 is a cross-sectional view of a display panel on which a cuttingline and an inspection pattern are formed, taken along the line II-II′of FIG. 8, according to an embodiment of the inventive concept;

FIG. 10 is a plan view illustrating a process of delaminating a pad areaportion of a display panel according to an embodiment of the inventiveconcept;

FIG. 11 is a plan view illustrating a process of checking whether aninspection pattern exists according to an embodiment of the inventiveconcept;

FIGS. 12A and 12B are plan views illustrating an inspection patternaccording to an embodiment of the present invention; and

FIG. 13 is a perspective view illustrating equipment for manufacturing adisplay device according to an embodiment of the inventive concept.

DETAILED DESCRIPTION

Like reference numerals refer to like elements throughout. Also, in thefigures, the dimensions of components may be exaggerated for clarity ofillustration. As used herein, the term “and/or” includes any and allcombinations of one or more of the associated listed items.

It is to be understood that although the terms “first” and “second” areused herein to describe various elements, these elements should not belimited by these terms. Rather, these terms are used to distinguish onecomponent from other components. For example, without departing from thescope of the present invention, a “first” element could be termed a“second” element, and, similarly, a “second” element could be termed a“first” element. The terms of a singular form may include plural formsunless described to the contrary.

Also, spatially relative terms, such as “below,” “lower,” “above,” and“upper,” may be used herein for ease of description to describe anelement and/or a feature's relationship to another element(s) and/orfeature(s) as illustrated in the drawings. The terms may be a relativeconcept and described based on directions expressed in the drawings.

The meaning of “include” or “comprise” specifies a property, a region, afixed number, a step, a process, an element, and/or a component, butdoes not exclude other properties, regions, fixed numbers, steps,processes, elements, and/or components.

A method for manufacturing a display device according to one or moreembodiments of the inventive concept includes: a process of providing awork panel including a work substrate including a plurality of displayunits each including a display area and a pad area, and a workprotective film attached onto the work substrate, a process ofseparating a plurality of display units from the work panel, eachincluding a display unit of the plurality of display units and aprotective film unit of the work protective film corresponding to thedisplay unit, a process of forming a cutting line in the protective filmso as to correspond to a boundary between the display area and the padarea, a process of forming an inspection pattern in which the protectivefilm unit in a pad area portion of the protective film unit, whichcorresponds to the pad area of the display unit, is partially removed ina thickness direction, a process of delaminating the pad area portion ofthe protective film unit along the cutting line, and a process ofchecking whether the inspection pattern exists on the pad area of thedisplay unit. Herein, a method for manufacturing a display device willbe described with reference to FIGS. 1 to 11.

FIG. 1 is a plan view illustrating a process of providing a worksubstrate according to an embodiment of the inventive concept; FIG. 2 isa plan view of a display unit according to an embodiment of theinventive concept; and FIG. 3 is an equivalent circuit diagram of apixel according to an embodiment of the inventive concept. Referring toFIGS. 1 to 3, a process of providing a work substrate including aplurality of display units will be described.

As illustrated in FIG. 1, a work substrate 100 includes a plurality ofdisplay units 200.

The work substrate 100 is defined by an active area 100-1 on which aplurality of display areas are formed and a non-active area 100-2 thatis a portion except for the active area 100-1. The active area 100-1 ofthe work substrate 100 may be an area on which a plurality of displayunits 200 are formed through any of processes, such as deposition,patterning, thin-film formation, and etching, and, in an embodiment, theplurality of display units 200 may be provided at a same time by using asame process.

Each of the display units 200 includes a display area 210 and a pad area220. The display unit 200 may be provided in plurality, and theplurality of display units 200 may be spaced apart from each other andarranged on the work substrate 100.

One display unit 200 will be described with reference to FIGS. 2 and 3.FIG. 2 illustrates a planar displacement relationship between wires SGLand pixels PX, which are included in the display unit 200.

As illustrated in FIG. 2, the display area 210 of the display unit 200includes a pixel area DA and first and second surrounding areas NDA1,NDA2 on a plane. In an embodiment, the first surrounding area NDA1 maybe defined along an edge of the pixel area DA.

Each of the display units 200 may include a driving circuit GDC, aplurality of wires SGL (herein, referred to as “wires”), a plurality ofsignal pads PD (herein, referred to as “signal pads”), and a pluralityof pixels PX (herein, referred to as “pixels”). The pixels PX aredisposed on the pixel area DA. In an embodiment, each of the pixels PXincludes an organic light emitting diode OLED and a pixel drivingcircuit connected thereto. The driving circuit GDC, the wires SGL, andthe pixel driving circuit may be included in a pixel element layer CL(see FIG. 5) that will be described later.

The driving circuit GDC may include a scan driving circuit. The scandriving circuit generates a plurality of scan signals (herein, referredto as “scan signals”) and sequentially outputs the scan signals to aplurality of scan lines GL (herein, referred to as “scan lines”). Thescan driving circuit may further output another control signal to adriving circuit of each of the pixels PX.

The scan driving circuit may include a plurality of thin-filmtransistors (herein, referred to as “transistors”) formed through a sameprocess as that of the driving circuit, e.g., a low temperaturepolycrystalline silicon (LTPS) process or a low temperaturepolycrystalline oxide (LTPO) process.

In an embodiment, the wires SGL includes scan lines GL, data lines DL, apower line PL, and a control signal line CSL. Each of the scan lines GLis connected to a corresponding pixel PX of the pixels PX, and each ofthe data lines DL is connected to the corresponding pixel PX of thepixels PX. The power line PL is connected to the pixels PX. The controlsignal line CSL may provide control signals to the scan driving circuit.

The wires SGL overlap the pixel area DA, the surrounding area NDA1, anda non-display area NDA2 (see FIG. 5). Each of the signal pads PD isconnected to a corresponding wire SGL of the wires SGL.

Substantially, a line part constitutes most of the wires SGL and isconnected to the pixel PX. The line part is connected to transistors T1and T2 (see FIG. 3) of the pixel PX. The line part may have a singlelayer or multi-layer structure and include a single body or two or moreportions. The two or more portions may be disposed on layers differentfrom each other and connected to each other through a contact hole (notshown) passing through an insulation layer (not shown) disposed betweenthe two or more portions.

The pad area 220 includes a plurality of alignment marks MS. In anembodiment of the inventive concept, the alignment marks MS are disposedon mutually corresponding positions of both ends of the pad area 220,but the inventive concept is not limited thereto. The alignment mark MSis located at a first distance L1 and a second distance L2,respectively, from a long side and a short side of the display unit 200.In an embodiment, the alignment mark MS may be formed in a process ofpatterning the wires SGL. In an embodiment, the alignment mark MS may beformed in a same layer as that of one of the wires SGL, and, in anexemplary embodiment, may be formed in a same layer as that of anuppermost wire of the wires SGL.

FIG. 3 exemplarily illustrates one pixel PX of the plurality of pixelsPX, which is connected to one scan line GL, one data line DL, and thepower line PL.

The pixel PX that is a pixel driving circuit for driving an organiclight emitting diode OLED includes a first transistor T1 (or a switchingtransistor), a second transistor T2 (or a driving transistor), and acapacitor Cst. A first power voltage ELVDD is provided to the secondtransistor T2, and a second power voltage ELVSS is provided to theorganic light emitting diode OLED. The second power voltage ELVSS may beless than the first power voltage ELVDD.

The first transistor T1 outputs a data signal applied to the data lineDL in response to a scan signal applied to the scan line GL.

The capacitor Cst charges a voltage corresponding to a data signalreceived from the first transistor T1.

The second transistor T2 is connected to the organic light emittingdiode OLED. The second transistor T2 controls a driving current flowingthrough the organic light emitting diode OLED in correspondence to acharge amount stored in the capacitor Cst.

The organic light emitting diode OLED may be a front light emittingdiode or a rear light emitting diode. Also, the organic light emittingdiode OLED includes an organic light emitting layer disposed between afirst electrode (not shown) and a second electrode (not shown). Theorganic light emitting diode OLED emits light during a turn-on sectionof the second transistor T2. However, embodiments of the inventiveconcept are not limited to the above-described constitution of the pixelPX. For example, the pixel PX may have any of various constitutions.

Although the display element is described as an organic light emittingdisplay element in this embodiment, the display element may include aliquid crystal cell, an electrophoretic element, or an electrowettingelement, for example.

FIG. 4 is a plan view illustrating a process of attaching a workprotective film according to an embodiment of the inventive concept; andFIG. 5 is a cross-sectional view of a work panel, taken along the lineI-I′ of FIG. 4, according to an embodiment of the inventive concept.

A work protective film 300 includes a protective film unit 300-1 and anon-active film area 300-C respectively corresponding to the active area100-1 and the non-active area 100-2 (see FIG. 1).

The protective film unit 300-1 includes a display film area 310 and apad film area 320 respectively corresponding to the display area 210 andthe pad area 220 of the display unit 200 (see FIG. 1).

The work protective film 300 is attached onto the work substrate 100 onwhich the display units 200 are formed. Accordingly, a work panel 400 isprovided in which the work protective film 300 is attached onto the worksubstrate 100.

The work protective film 300 may prevent or substantially preventexternal moisture or foreign substances from being introduced into theplurality of display units 200 or prevent or substantially prevent acrack from being generated during a process. In an embodiment, the workprotective film 300 may be formed of a material having flexibility,e.g., a polymer resin.

FIG. 5 is a cross-sectional view illustrating one display panel WP inwhich the protective film unit 300-1 is attached to one display unit200-1.

The display panel WP includes a display unit 200-1 and a protective filmunit 300-1 that overlaps the display unit 200-1 in a plane.

A protective film unit 300-1, including a display film area 310-1 and apad film area 320-1, may be coupled to an uppermost layer of a displayunit 200-1 through an adhesive layer AL. In an embodiment, the uppermostlayer of the display unit 200-1 may have a stepped portion depending onan area.

In an embodiment, the adhesive layer AL may have an adhesion force of atop surface to which the protective film unit 300-1 is attached, whichis greater than that of a bottom surface to which a thin-filmencapsulation layer TFE is attached, such that the adhesive layer AL maybe easily removed from the display unit 200-1.

In an embodiment, an empty space having a first thickness TH1 may beformed between the adhesive layer AL and the pad area 220-1. Since adisplay element layer OL is not deposited on the pad area 220-1, astepped portion is generated in the pad area 220-1, such that the emptyspace having the first thickness TH1 is formed. The circuit elementlayer CL is patterned in the pad area 220-1 to form the wires SGL (seeFIG. 2), and, then, the adhesive layer AL and the protective film unit300-1 are laminated thereon.

In an embodiment, the adhesive layer AL has a second thickness TH2 ofabout 50 μm to about 75 μm, and the first thickness TH1 is about 30 nmto about 70 nm, such that a flat surface shape of the work protectivefilm 300 is not affected by the empty space. For purposes ofillustration, the first thickness TH1 is shown enlarged more than thatof the protective film unit 300-1.

In an embodiment, the display unit 200-1 includes a base layer BL, acircuit element layer CL disposed on the base layer BL, a displayelement layer OL, a thin-film encapsulation layer TFE, an adhesive layerAL, and the protective film unit 300-1. Although not shown, the displayunit 200-1 may further include functional layers such as a reflectionprotection layer and a refractive index adjusting layer.

In an embodiment, the base layer BL may include a synthetic resin film.A synthetic resin layer is formed on the work substrate 100 (see FIG. 1)used for manufacturing the display unit 200-1. Thereafter, a conductivelayer, an insulation layer, and the like are formed on the syntheticresin layer. Although the synthetic resin layer may include apolyimide-based resin layer, an embodiment of the inventive concept isnot limited to a particular material of the synthetic resin layer. Forexample, the base layer BL may include a glass substrate, a metalsubstrate, and/or an organic/inorganic composite substrate.

The circuit element layer CL includes at least one intermediateinsulation layer and a circuit element. In an embodiment, theintermediate insulation layer includes at least one inorganicintermediate layer and at least one organic intermediate layer. Thecircuit element includes a driving circuit GDC and the wires SGL (seeFIG. 2), and the pixel driving circuit.

In an embodiment, the pixel element layer CL may be formed through aprocess of forming an insulation layer and a conductive layer by using acoating or deposition process and a process of patterning a conductivelayer and/or a semiconductor layer by using a photolithography process,but is not limited thereto.

The display element layer OL includes a light emitting element. Thedisplay element layer OL may include organic light emitting diodes. Thedisplay element layer OL may further include a pixel defining layer andan organic layer.

The thin-film encapsulation layer TFE seals the display element layerOL. The thin-film encapsulation layer TFE includes at least oneinsulation layer. The thin-film encapsulation layer TFE according to anembodiment of the inventive concept may include at least one inorganiclayer (herein, referred to as an “encapsulation inorganic layer”).

The encapsulation inorganic layer protects the display element layer OL,and an encapsulation organic layer protects the display element layer OLfrom foreign substances such as dust particles. In an embodiment, theencapsulation inorganic layer may include a silicon nitride layer, asilicon oxynitride layer, a silicon oxide layer, a titanium oxide layer,or an aluminum oxide layer. Although the encapsulation organic layer mayinclude an acrylic-based organic layer, embodiments of the inventiveconcept are not limited thereto.

FIG. 6 is a plan view illustrating a process of separating individualdisplay panels from the work panel. A first device CT1 is used to cutthe work panel 400-1 into an individual display panel WP-1 correspondingto the active area 100-1 (see FIG. 1). The first device CT1 may cut thedisplay panel WP-1 while moving in first and second directions D1 and D2along a cutting line TL formed on an edge of the display panel WP-1.Accordingly, the plurality of display units formed on the work panel400-1 is separated into the one or more individual display units 200-1.For example, the first device CT1 may irradiate a laser to cut the workpanel 400-1. Although not shown, in an embodiment, the first device CT1may include a laser oscillation part, a laser optical part, and a lasercollecting part.

FIG. 7 is a plan view of a display panel on which a cutting line isformed according to an embodiment of the inventive concept.

A cutting line HC is formed along a boundary between a display film area310-1 and a pad film area 320-1. The cutting line HC is formed by usinga second device CT2. In an embodiment, the second device may use thesame equipment as that of the first device CT1. Here, an intensity ofthe laser may be adjusted to adjust a depth of a surface to be cut. Thecutting line HC may be a reference line of an area that is an object tobe delaminated in a following delamination process.

FIG. 8 is a plan view of a display panel on which an inspection patternis formed according to an embodiment of the inventive concept; and FIG.9 is a cross-sectional view of a display panel on which a cutting lineand an inspection pattern are formed, taken along the line II-II′ ofFIG. 8, according to an embodiment of the inventive concept. The samereference numerals are assigned to the same components as those in FIGS.1 to 5, and a duplicate description will be omitted. Herein, a cuttingline HC and a cut cross-section of an inspection pattern IP1 will bedescribed in further detail with reference to FIGS. 8 and 9.

The inspection pattern IP1 is formed by removing a portion of aprotective film unit 300-2 in a display panel WP-2 in a thicknessdirection. In the protective film unit 300-2, a cutting line HC isformed along a boundary between a display film area 310-2 and the padfilm area 320-2. For example, the inspection pattern IP1 may be formedin plurality in the pad film area 320-2, and, in an embodiment, theinspection pattern IP1 may be formed in one portion of the pad film area320-2. Also, the inspection pattern IP1 may have any of various shapes.Although not shown, in an embodiment, the inspection pattern IP1 mayhave a scratch shape, as an example, and may be formed in one portion ofthe display panel WP-2 in a direction of a long side or a short side ofthe display panel WP-2. The inspection pattern IP1 is used to inspectwhether delamination has succeeded after the delamination process. In anembodiment, the inspection pattern IP1 is formed by using a third deviceCT3. In an embodiment, the third device may use the same equipment asthat of the first device CT1. Here, an intensity of the laser may beadjusted to adjust a depth of a surface to be cut. Although the shape ofthe inspection pattern IP1 may include various embodiments, anembodiment of the inventive concept is not limited thereto.

The cutting line HC allows the protective film unit 300-2 to becompletely removed in a thickness direction of the display panel WP-2such that a portion of the adhesive layer AL disposed between anuppermost layer of the display panel WP-2 and the protective film unit300-2 is exposed to the outside. In an embodiment, the adhesive layer ALremains in a portion on which the cutting line HC is formed and has athickness of about 25 μm to about 40 μm. When the adhesive layer ALremaining after the cutting line HC is formed has a thickness less thanabout 25 μm, the protective film unit 300-2 may be detached before thedelamination process, and moisture or foreign substances may beintroduced. When the adhesive layer AL remaining has a thickness greaterthan about 40 μm, delamination failure due to an adhesion force may beprevented from being generated.

In an embodiment, the protective film unit 300-2 remaining after theinspection pattern IP1 is formed may have a thickness of about 25 μm toabout 40 μm. When the remaining protective film unit 300-2 has athickness less than about 25 μm, the protective film unit 300-2 aroundthe inspection pattern IP1 may be prevented from being detached. Whenthe remaining protective film unit 300-2 has a thickness greater thanabout 40 μm, an error, which is generated when checking whether theinspection pattern IP1 exists due to a small thickness of the inspectionpattern IP1 in a following process of checking whether the inspectionpattern exists, may be prevented.

FIG. 10 is a plan view illustrating a process of delaminating showing astep of peeling off the corresponding protective film of the pad regionportion of a display panel WP-3. The same reference numerals areassigned to the same components as those in FIG. 1 to FIG. 5, andredundant description is omitted.

The process of delaminating the display panel WP-3 uses a delaminationdevice PM. An object to be delaminated is a pad film area 320-3 portion.In a protective film unit 300-3, a cutting line HC is formed along aboundary between a display film area 310-3 and the pad film area 320-3.Although not shown, the delamination device PM may weaken an adhesionforce of an edge of the object to be delaminated so as to reduce afailure probability of the delamination work before the delaminationprocess is performed. In an embodiment, for example, the edge of theobject to be delaminated may be struck to weaken the adhesion force ofthe adhesive layer AL, and, then, the delamination process may beperformed. Although the delamination device PM may include any ofvarious embodiments, such as a delamination device using a roller and adelamination device using a grip, an embodiment of the inventive conceptis not limited thereto.

Referring to FIG. 11, a process of checking whether the inspectionpattern exists after the process of delaminating the pad film areaportion 320-3 (see FIG. 10) corresponding to the pad area 220-2 of adisplay panel WP-4 is performed. The process of checking whether theinspection pattern IP1 exists is performed to check whether thedelamination has succeeded, and an inspection device IS is used for theprocess. In an embodiment, the inspection device IS may include a cameramodule and an alignment mark recognition module. The inspection deviceIS may distinguish whether the object to be delaminated is delaminatedby the naked eye of an inspector through the camera module. That is, ina protective film unit 300-4 including a display film area 310-4, a padfilm area corresponding to the pad film area 320-3 (see FIG. 10) onwhich the inspection pattern IP1 is formed is the object to bedelaminated, and the inspection pattern IP1 formed by removing protectfilm may not be distinguished by the naked eye when the delamination issuccessively performed. When the delamination is successively performed,the wires SGL, the pads PD, and the alignment mark MS are exposed to theoutside.

When the delamination has failed, the inspection pattern IP1 may beobserved while the inspection is performed. When the delamination hasfailed, the delamination process may be re-performed.

When the delamination process is successively performed, the alignmentmark MS exposed to the outside in the pad area 220-2 may be recognizedthrough the alignment mark recognition module of the inspection deviceIS. A process of checking whether the display units are cut by a desirednumber in the process of separating the plurality of display unitsthrough the recognition of the alignment mark MS may be included. Forexample, the alignment mark MS has a first distance L1 and a seconddistance L2, respectively, from a long side and a short side of thedisplay unit 200. The alignment mark MS may be measured by the alignmentmark recognition module of the inspection device IS, and, then, thedisplay unit 200 may be determined as a qualified product when the firstdistance L1 and the second distance L2 are within an error range (e.g.,a preset error range). When deviated from the error range, the displayunit may be determined as a failure.

According to an embodiment of the inventive concept, as the inspectiondevice IS that is the same equipment is used, the process of checkingwhether the delamination has succeeded and the process of measuring thelengths of the long side and the short side of the display unit may beperformed at the same time. Whether the delamination has succeed may bedetermined by checking whether the inspection pattern IP1 is observedthrough the camera module of the inspection device IS, and, when theinspection pattern IP1 is removed, the lengths of the long and shortsides of the display unit 200 from the alignment mark MS may be measuredthrough the alignment mark recognition module of the inspection deviceIS. The above process may be performed through module change of theinspector in the same process using the inspection device IS that is thesame equipment.

Typically, the process of inspecting whether the delamination hassucceeded is performed by a contact-type inspection using a method ofpressing the pad area. Since the contact-type inspection is performed byoperating the equipment in a nanometer range, the equipment contacts thepad area to generate a crack due to an error of the equipment during theinspection process.

According to an embodiment of the inventive concept, the process ofinspecting whether the inspection pattern IP1 exists and the process ofmeasuring the lengths of the long and short sides of the display unit200 may be performed at the same time by using the inspection device ISthat is the same equipment. As the typical contact-type inspection ischanged to the non-contact-type inspection in the above-describedprocess by using the same equipment, reduction in production yield dueto the crack generation may be avoided.

FIGS. 12A and 12B are plan views illustrating an inspection patternaccording to an embodiment of the present invention.

In an embodiment, an inspection pattern IP2 may be formed on aprotective film unit 300-5 corresponding to a pad film area 320-5 byoverlapping at least one alignment mark MS of the plurality of alignmentmarks formed on the pad area 220 (see FIG. 2). In the protective filmunit 300-5, a cutting line HC is formed along a boundary between adisplay film area 310-5 and the pad film area 320-5. In an embodiment, aprocess of inspecting whether the inspection pattern IP2 exists and aprocess of measuring lengths to the long and short sides of the displayunit 200 (see FIG. 2) are performed at the same time and, as thealignment mark MS and the inspection pattern IP2 overlap each other, aprocess time may be reduced, and existence of the inspection pattern IP2may be further intuitionally checked.

In an embodiment, an inspection pattern IP3 may be formed on theprotective film unit 300-5 corresponding to the pad film area 320-5 byoverlapping at least one wire of the plurality of wires SGL formed onthe pad area 220 (see FIG. 2). In an embodiment, a process of inspectingwhether the inspection pattern IP3 exists and a process of checkingwhether the wires SGL are failed are performed at the same time byoverlapping the alignment mark MS with the wires SGL, and theabove-described effect may be achieved. Positions at which theinspection patterns are formed may include any of various embodiments onthe protective film unit 300-5 corresponding to the pad film area 320-5,and an embodiment of the inventive concept is not limited thereto.

As described above, although a method for manufacturing the displaydevice by using the work substrate 100 (see FIG. 1) is described, anembodiment of the inventive concept is not limited thereto. According toan embodiment of the inventive concept, the display device may bemanufactured by using the display unit 200 (see FIG. 2) cut from thework substrate 100. Description of components corresponding to those inFIGS. 2, 7, and 8 will not be provided, and like reference numerals inthe drawings denote like elements.

According to an embodiment of the inventive concept, a method formanufacturing a display device may include: a process of providing adisplay unit 200 including a display area 210 and a pad area 220; aprocess of attaching a protective film unit including a display filmarea 310 and a pad film area 320 in correspondence to the display area210 and the pad area 220 onto the provided display unit 200; a processof forming a cutting line so as to correspond to a boundary between thedisplay film area 310 and the pad film area 320; a process of forming aninspection pattern that is partially removed in a thickness direction ofa protective film unit 300-1 on the pad film area 320 of the protectivefilm unit 300-1, a process of delaminating the protective film unit300-1 corresponding to the pad film area 320 along a cutting line; and aprocess of checking whether an inspection pattern exists on the padarea.

FIG. 13 is a perspective view illustrating equipment for manufacturing adisplay device according to an embodiment of the inventive concept.Description of components corresponding to those in FIGS. 1, 4, and 8will not be provided, and like reference numerals in the drawings denotelike elements.

Display device manufacturing equipment PC, according to an embodiment,includes a main body ML, a laser device MCT, a delamination device MPM,an inspection device MIS, and a control device CM. The laser device MCT,the delamination device MPM, and the inspection device MIS may becoupled to the main body ML. The laser device MCT may cut the work panel400 and separate it into a plurality of display panels. Each of thedisplay panels WP includes a protective film unit superimposed on andattached to the display unit and the display unit. In an embodiment,while the display device manufacturing equipment PC for dividing thework panel 400 into the display panel WP moves on the work panel 400 ina first direction D1 and a second direction D2 (the first direction D1and the second direction D2 intersect a third direction D3), a laser isirradiated along an edge of the plurality of display panel WP and passesthrough a bottom surface of the work panel 400, such that the work panel400 is divided. In an embodiment, the laser device MCT may entirelyremove a protective film unit 300-1 (see FIG. 4) at a boundary between adisplay film area 310 (see FIG. 4) and a pad film area 320 (see FIG. 4)in a thickness direction to form a cutting line HC. Also, the laserdevice MCT may form an inspection pattern IP, from which a portion isremoved in a thickness direction, on a portion of the pad film area 320.The laser device MCT may irradiate a laser having various intensity.Accordingly, cutting lines having thicknesses different from each othermay be formed.

The delamination device MPM removes the pad film area 320 that is anobject to be delaminated along the cutting line HC. In an embodiment,although not shown, the delamination device MPM may weaken an adhesionforce of an edge of the object to be delaminated so as to reduce afailure probability of the delamination work before the delaminationprocess is performed. For example, the edge of the object to bedelaminated may be struck to weaken the adhesion force of an adhesivelayer AL (see FIG. 5), and, then, the delamination process may beperformed. Although the delamination device MPM may include any ofvarious embodiments, such as a delamination device using a roller and adelamination device using a grip, an embodiment of the inventive conceptis not limited thereto.

In an embodiment, the inspection device MIS may include a camera moduleand an alignment mark recognition module. The inspection device MIS maydistinguish whether the object to be delaminated is delaminated by thenaked eye of an inspector through the camera module. That is, when thedelamination is successively performed by the delamination device MPM,the inspection pattern IP may not be distinguished by the naked eye.When the delamination has failed, the inspection pattern IP may beobserved, and re-delamination may be performed by the delaminationdevice MPM.

When the delamination process is successively performed, an alignmentmark MS exposed to the outside from a pad area 220-2 (see FIG. 11) maybe recognized through the alignment mark recognition module of theinspection device MIS. Whether the plurality of display units are cut bya desired number in the process of separating the plurality of displayunits may be checked through the recognition of the alignment mark MS.

In an embodiment, the control device CM may be electrically connected tothe laser device MCT, the delamination device MPM, and the inspectiondevice MIS through the main body ML. In an embodiment, the controldevice CM may adjust an intensity of a wavelength and an irradiationtime to adjust the laser to have a desired intensity. The control deviceCM may control whether the pad film area 320 is delaminated after thelaser irradiation. Also, the control device CM may perform a process ofchecking whether the delamination has succeeded by controlling thecamera module and the alignment mark recognition module of theinspection device MIS and whether the display units are cut by a desirednumber through the alignment mark MS recognition.

The display device manufacturing equipment PC according to an embodimentof the inventive concept may perform the laser irradiation, thedelamination, and the inspection of each process by using the sameequipment. Thus, a manufacturing process time may be shortened incomparison to a time required when different equipment is used for eachprocess, and, thus, productivity may be improved.

As described above, in the process of inspecting whether thedelamination is performed after the process of delamination of the padarea, whether the delamination is performed may be inspected in anon-contact manner instead of the typical contact-type inspection byusing the pressing method. Thus, the components mounted inside, such asthe pad and the wire that are disposed below the protective film, may beprevented or substantially prevented from being damaged.

Although some exemplary embodiments of the present invention have beendescribed, it is to be understood that the present invention should notbe limited to these exemplary embodiments, but various changes andmodifications can be made by one of ordinary skill in the art within thespirit and scope of the present invention as herein claimed.

What is claimed is:
 1. A method for manufacturing a display device, themethod comprising: providing a work panel comprising a work substratecomprising a plurality of display units each comprising a display areaand a pad area, and a work protective film attached onto the worksubstrate; forming a cutting line in the work protective film so as tocorrespond to a boundary between the display area and the pad area andalong a thickness direction of the work protective film; forming aninspection pattern by partially removing the work protective film alongthe thickness direction of the work protective film overlapping the padarea; cutting the work panel to separate into the display units;delaminating the work protective film overlapping the pad area in thedisplay units; and checking whether the inspection pattern exists in thepad area of the display units.
 2. The method of claim 1, wherein the padarea comprises a plurality of wires and a plurality of alignment marks,and the inspection pattern overlaps at least one of the plurality ofalignment marks.
 3. The method of claim 2, wherein the inspectionpattern overlaps at least one of the plurality of wires.
 4. The methodof claim 2, wherein the plurality of alignment marks is formed on a samelayer as that of a wire of the plurality of wires.
 5. The method ofclaim 2, further comprising measuring distances from an alignment markof the plurality of alignment marks to each of a long side and a shortside of the display unit.
 6. The method of claim 5, wherein measuringdistances from the alignment mark to each of the long side and the shortside of the display unit and checking whether the inspection patternexists are performed at the same time.
 7. The method of claim 1, whereinan adhesive layer is between the work panel and the work protectivefilm, and wherein the cutting line is formed by completely removing thework protective film in the thickness direction of the work protectivefilm along the boundary between the display area and the pad area andexposing the adhesive layer to the outside.
 8. The method of claim 7,wherein a thickness in the adhesive layer overlapping the cutting lineis 25 μm to about 40 μm.
 9. The method of claim 1, wherein each of thedisplay units comprises a base substrate, a circuit element layer, adisplay element layer, and a thin-film encapsulation layer, which aresequentially laminated.
 10. A method for manufacturing a display device,the method comprising: providing a work panel comprising a worksubstrate comprising a plurality of display units each comprising adisplay area and a pad area, a work protective film on the work panel,and an adhesive member disposed between the work panel and the workprotective film to bond the work panel and the work protective film;forming a cutting line in the work protective film so as to correspondto a boundary between the display area and the pad area; forming aninspection pattern in the work protective film overlapping the pad area;and cutting the work panel to separate into the display units, whereinthe cutting line is formed by completely removing the work protectivefilm in a thickness direction of the work protective film along theboundary between the display area and the pad area and exposing theadhesive member to the outside, and the inspection pattern is formed bypartially removing the work protective film in the thickness directionof the work protective film.
 11. The method of claim 10, furthercomprising delaminating the work protective film overlapping the padarea in the display units; and checking whether the inspection patternexists in the pad area of the display units.
 12. The method of claim 11,wherein the pad area comprises a plurality of wires and a plurality ofalignment marks, and the inspection pattern overlaps at least one of theplurality of alignment marks.
 13. The method of claim 12, wherein theinspection pattern overlaps at least one of the plurality of wires. 14.The method of claim 12, wherein the plurality of alignment marks isformed on a same layer as that of a wire of the plurality of wires. 15.The method of claim 12, further comprising measuring distances from analignment mark of the plurality of alignment marks to each of a longside and a short side of the display unit.
 16. The method of claim 11,wherein a thickness in the adhesive member overlapping the cutting lineis 25 μm to about 40 μm.